Matrix S3600 SILVER SERIES Operation & Installation Manual

Reverse osmosis system

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OPERATION & INSTALLATION MANUAL

MATRIX S3600 SILVER SERIES

REVERSE OSMOSIS

SYSTEM

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Page 1 OPERATION & INSTALLATION MANUAL MATRIX S3600 SILVER SERIES REVERSE OSMOSIS SYSTEM...
Page 2: Table Of Contents
PRODUCT WATER CONDUCTIVITY MEASUREMENT ................17 PRODUCT AND CONCENTRATE FLOW MEASUREMENT ................17 OPERATING PRESSURE MEASUREMENT ....................... 17 FEED PRESSURE MEASUREMENTS ........................17 MATRIX WATERMAKER LOG SHEET ......................19 INSTALLATION INSTRUCTIONS ................20 PIPING MATERIAL ..............................20 FEED PIPING ................................20 CONCENTRATE PIPE ............................
Page 3 ROUTINE MAINTENANCE ................... 33 SILVER SERIES MAINTENANCE SCHEDULE ....................33 MAINTENANCE OF PRE-FILTRATION COMPONENTS ................34 TO CHANGE THE BAG ............................36 THE WATERMAKER ....................38 MEMBRANE STERILIZATION AND CLEANING PROCEDURES ....... 39 TROUBLESHOOTING ....................44 ENGINEERING DATA ....................47 COMPONENT ILLUSTRATIONS .................
Page 5: Preface
Reverse Osmosis, and instruct you on how to properly operate the MATRIX watermaker system. Before you operate your new MATRIX watermaker it is recommended that you READ THIS MANUAL FIRST! Familiarize yourself with this manual now so that in the event of...
Page 6: A Discussion Of Reverse Osmosis
SEAWATER DESALINATION: A Discussion of Reverse Osmosis Seawater contains many kinds of solids dissolved in solution. The most prevalent is common table salt (Sodium Chloride). Present as well are other minerals, including Calcium, Magnesium, Sulfate, Bicarbonate Alkalinity, Silica, and others. The sum of these dissolved solids is referred to as the Total Dissolved Solids or T.D.S.
Page 7 the membranes because there would be no water left to flush away the solids, which do not pass through the membranes. Normal recoveries for small seawater conversion units are in the range of 15-30%. At 20% recovery, for every 100 gallons of raw water fed to the RO system, 20 gallons are recovered as purified water and 80 gallons are routed to waste as concentrated rejected salts (brine).
Page 8: The Main Components Of A Watermaker
A common method of pretreatment is pre-filtration, which removes most of the suspended matter from the feedwater. Although the RO system incorporates a pre-filter, some very small particles pass through and have a tendency to collect on the membranes. In time - ranging from months to years, depending on what is in the water - enough particles collect inside the membrane housing that the membranes require cleaning.
Page 9 High-pressure pumps or booster pumps vary in design, usually depending on a specific application. Matrix uses only positive-displacement, plunger type high-pressure pumps. Pressure vessels house the membranes for a water maker. They are manufactured from aluminum, stainless steel, or fiberglass.
Page 10: The Subcomponents And Accessories
THE SUBCOMPONENTS AND ACCESSORIES Freshwater Flush Assembly In order to extend the life of the membranes, MATRIX offers 4 fresh water flush options, Manual, Solenoid Operated, Automatic, and Automatic with a flush tank. The first three options use ship’s fresh water to flush the unit, and include a carbon filter to remove any residual chlorine from the ship’s fresh water supply.
Page 11 Chemical Valve Assembly (Optional) There are two (2) three way chemical valves that are available as an option that can be plumbed to the suction port of the feed pump and the concentrate discharge on the unit. Quick release fittings on one side of the valves enable chemical hoses to be stored when the watermaker is in normal operation.
Page 12 Electrical control panels are used to provide the sequencing needed to have a sequenced startup, and shut down of a reverse osmosis unit. They also house the electrical controls and instruments. Matrix uses electric control panels that are constructed to the NEMA 4X standard. The 4X rating ensures that the electrical components will be protected from water, even if the water is sprayed on the panel under pressure.
Page 13: Design Considerations
DESIGN CONSIDERATIONS WATER TEMPERATURE EFFECT The water temperature significantly affects the product water flow rate through the membrane. At any given pressure this flow increases with increasing feedwater temperatures and decreases at lower feedwater temperatures. The system design is based on expected product water output at 77°F. The water temperature conversion chart illustrates the percent variance observed in product water flow at temperatures other than the design basis (77°F).
Page 14 in the Design Data Sheet. At lower brine flows, concentration of sparingly soluble salts will foul the membrane surface. High brine velocities can also be a source of difficulty. At excessive flows the elements are subjected to severe stress and physical damage such as telescoping, glue-line fracture, etc.
Page 15: Temperature Correction Table
TEMPERATURE CORRECTION TABLE °C CORRECTION °C CORRECTION °F CORRECTION °F CORRECTION FACTOR FACTOR FACTOR FACTOR 3.64 0.97 3.47 0.90 3.23 0.94 3.18 0.88 3.03 0.91 2.93 0.82 2.78 0.88 2.68 0.79 2.58 0.85 2.47 0.79 2.38 0.83 2.29 0.77 2.22 0.80 2.14 0.75...
Page 16 Production Capacity vs. Temperature Temperature (Deg F) Operating Pressure vs. Temperature Temperature (Deg F)
Page 17: Operating Instruments
OPERATING INSTRUMENTS PRODUCT WATER CONDUCTIVITY MEASUREMENT The conductivity meter that is located at the front of the electrical panel measures the electrical conductivity of the product water. The meter is equipped with an adjustable high point setting that allows the poor quality water to be dumped to waste.
Page 19: Matrix Watermaker Log Sheet
MATRIX WATERMAKER LOG SHEET Date System Media/ Bag Media/ Fine Fine Filter Mem. Feed Product Conc. Product Product Initial Hours Filter Filter Outlet Press. Flow Flow Quality Quality Inlet Filter Inlet Panel Hand Outlet (mmho) Meter (mmho) Date Maintenance / Comments...
Page 20: Installation Instructions
NOTE: Iron, steel, copper, galvanized, or aluminum materials should never be used. FEED PIPING MATRIX recommends to increase the feedwater piping above the inlet size for the system by one pipe diameter (except for stainless steel) whenever possible. Also increasing the through-hull and seacock in marine applications, by one pipe size, is normally a good practice.
Page 21 holding tank. The air gap will ensure that no stored water (which may contain chlorine) can be drawn back into the watermaker when the watermaker is not in operation. CAUTION: Rupture of the membrane envelope may occur if the product backpressure is exceeded.
Page 22 If you desire to provide your own supply pump, contact Matrix so that we can ensure that the pressure and flow of the pump are sufficient, and that the control of the pump can be properly integrated into the watermaker control system.
Page 23 Once the head has been removed, mask off the tank internal threads with tape to protect the threads during media loading. Locate the first load associated with that particular tank. After the proper media is set aside for the tank, loading may begin. First scoop or pour the gravel into the opening on top of the tank where the head was.
Page 24 After the tank is loaded, and the plumbing has been replaced the tank can now be backflushed. The initial backwash will sometimes take two to four hours to discharge all of the loose material in the media. During this time, loosen the vent plugs located on the tank heads.
Page 25 contact in the control circuit causing the unit to shut down. The unit will automatically fresh flush after shutdown. No operator intervention is required when the unit is in automatic operating mode. Refer to the electrical schematic at the end of this manual for float switch wiring instructions.
Page 26: Operating Instructions
OPERATING INSTRUCTIONS MANUAL UNIT INITIAL START UP PROCEDURES Normally after installation of the R/O either a MATRIX technician or authorized representative should be present on initial system start up. In all cases, if working with electricity, a qualified electrician should be present.
Page 27 9. Once correct rotation has been verified, restart the supply pump by turning the Off/Run/Start switch to Start and while the supply pump is running, check for leaks. If leaks are observed turn off the control power and make necessary repairs. 10.
Page 28: Manual Unit Normal Operation
MANUAL UNIT NORMAL OPERATION 1. Turn the main breaker on. 2. Ensure all suction and discharge valves are in the correct position. 3. Ensure the high pressure-regulating valve is fully opened (counter-clockwise). 4. Turn the Off/Run/Start switch to the Start position. The Feed Pump running light will illuminate.
Page 29: Automatic Unit Initial Start Up Procedures
AUTOMATIC UNIT INITIAL START UP PROCEDURES Normally after installation of the R/O either a MATRIX technician or authorized representative should be present on initial system start up. In all cases, if working with electricity, a qualified electrician should be present.
Page 30 When no large air bubbles are visible in the water flow in the concentrate flowmeter, the unit can be started (see Startup and Shutdown Procedures) With the unit running, check for leaks. If leaks are observed, turn off the unit, and make necessary repairs.
Page 31: Automatic Unit Normal Operation
AUTOMATIC UNIT NORMAL OPERATION Prior to setting the unit to AUTO for the first time, run the unit in MANUAL to ensure that the high-pressure regulating valve is set to the correct position. Once this has been accomplished, shut the unit down. Place the MANUAL/AUTO switch in AUTO Turn the OFF/RUN/START switch to the RUN position.
Page 32: Automatic Unit Manual Start Up And Shut Down Procedures
AUTOMATIC UNIT MANUAL START UP AND SHUT DOWN PROCEDURES If external float switches are not installed, it will be necessary to install a jumper wire on terminals 3 and 4 in the control panel to simulate a normally closed contact from the product storage tank level switch.
Page 33: Routine Maintenance
Flush pump after each use with fresh water. Change pump oil first 50 hours and after every 500 hours with MATRIX Pump Oil. High Pressure Pump Motor – Grease motor every three months with MATRIX SRI No. 2 grease.
Page 34: Maintenance Of Pre-Filtration Components
Membranes – Clean membranes every six months with general cleaning chemicals or as needed. If there is suspected fouling then clean the membranes with the chemical that is best prescribed. Always sterilize the membranes when they will not be used for one week or more to prevent bacteria from growing.
Page 35 Although this system utilizes the finest prefiltration available, improper service can still result in this problem. By changing filters and not flushing out the chamber, or re-using old cartridges; a "sludge" of particle contaminated water will flow to the elements and some particles will become lodged within the brine spacer, or if large enough, plug the feedwater end of the element.
Page 36: To Change The Bag
1000-2000 pounds. The bag filters are non-corrosive and are rated up to 150 psi. operating pressure. There is no backflushing procedure for this type of filter. When the pressure gauge shows a pressure drop of 15 psi., simply remove the bag, and clean with fresh, dechlorinated water.
Page 37 CARTRIDGE FILTRATION Cartridge filter assemblies are provided for removal of suspended solids of 5 micron, or greater, that could damage the high-pressure pump and/or foul the membranes. A pressure gauge is provided to facilitate the monitoring of the feedwater supply pressure to the H.P.
Page 38: The Watermaker
Maintain the oil level in the crank end of the pump to one half the sight glass level. The oil must be changed after the first fifty-(50) hours of running. Always use MATRIX Pump Oil to maintain the warranty. Subsequent oil changes are at 500 hours or every three months.
Page 39: Membrane Sterilization And Cleaning Procedures
MEMBRANE STERILIZATION AND CLEANING PROCEDURES The following chemical cleaning procedures are intended to be applied through the use of a standard Matrix cleaning system. Cleaning should be performed only by qualified personnel. Contact Matrix for assistance if required. The quantity of mixed cleaning solution required is as follows:...
Page 40 MEMBRANE STERILIZATION PROCEDURES SOLUTION D-20 - FOR SHORT-TERM SHUTDOWN - (FOUR WEEKS OR LESS) SOLUTION E-25 - FOR LONG-TERM SHUTDOWN (FOUR WEEKS TO SIX MONTHS) STEP 1: Prepare Watermaker 1. Flush system with copious amounts of fresh, dechlorinated water. This step is to remove all saline water and chemicals from the system and membrane elements.
Page 41 RE-CIRCULATED UNDER "MINIMUM PRESSURE"! CHEMICAL SOLUTION TEMPERATURE MUST NEVER EXCEED 35°C (110°F). During recirculation, the temperature of the cleaning solution will rise. Do not allow the temperature to exceed 110 degF After re-circulation, close all inlet and discharge valves to isolate the watermaker and prevent the solution from draining out of the watermaker.
Page 42 CHEMICAL CLEANING INSTRUCTIONS FOR USE WITH A-10, A-20, B-10, C-15, and M5-SW Solutions STEP 1: Prepare Watermaker: 1. Flush system with copious amounts of fresh, dechlorinated water. This step is to remove all saline water and chemicals from the system and membrane elements. 2.
Page 43 RE-CIRCULATED UNDER "MINIMUM PRESSURE"! CHEMICAL SOLUTION TEMPERATURE MUST NEVER EXCEED 35°C (110°F). 2. During recirculation, visually inspect the condition of the cleaning solution. If the solution becomes very dirty, discard the solution and mix a new batch. When using cleaners A-10 and A-20 only, periodically, check the pH of the solution. The pH will normally fall as the membrane foulants are removed.
Page 44: Troubleshooting
TROUBLESHOOTING GENERAL After correct installation and start up of the MATRIX Watermaker by authorized personnel, most problems occur with the normal wear and tear of components. Many problems can be eliminated by following the correct maintenance procedures and also maintaining the operating logs described in this manual.
Page 45 Membrane Product Fouled Membranes Clean/ Replace Membrane   Quality Low Feedwater Salinity Increase Check Sea Water Salinity   Improper Chemical Consult MATRIX Service Pretreatment (Optional Department Equipment)   Conductivity Probe Needs Clean Probe Cleaning   RO Membrane Feed Pressure...
Page 46 Membrane Installation & Position of Brine Ring To install the membrane, observe that there is one outer seal (called the “Brine Seal”) on only one end of the membrane – SEE DRAWING. This “V-shaped” seal ensures that the feedwater goes through the membrane, not around the outside (path of least resistance).
Page 47: Engineering Data
ENGINEERING DATA...
Page 48: Component Illustrations
COMPONENT ILLUSTRATIONS...